Building construction



June 21, 1938. G. FQKOTRBATY BUILDING CON'STRUC'IIOIJ Filed July 31, 1957 lNVEN-TOR I Buy EKuhlmty ATTORNEY Patented June 21, 1938 UNITED STATES PATENT OFFICE.

2,121,037 BUILDING CONSTRUCTION Guy Felix Kotrbaty, Chestnut Hill, Pa. Application July 31, 1937, Serial No. 156,758

12 Claims.

This invention relates to improvements in selfsupporting building units adapted for use in walls and floors, roofs, and the application relates more particularly to such units having channel-shaped semi-stud and beam sections, with longitudinal keyways, as the load-supporting structural elements, spaced apart and held by a single panel, abutted semi-stud or beam elements being secured together as structural composites. by a plurality of keying means, and the open faces of the units being surfaced with continuous sheathing or other surfacing materials.

The present invention is concerned with structural units in which the side members form structural building members when abutted and interlocked with juxtaposed like members. The so-formed composite structural supporting members may be spaced apart on a given modulus and secured together by panelings or wall members to form a single face or wall section of an open I building unit, which will comprise two end structural composite stud or beam elements and an intermediate wall, fiooring, ceiling or roofing panel section. The panelings may be secured to the side or structural supporting members as by means of bolts, rivets, screws, screw nails, or equivalent securing means. Waterproof cements, including casein glues, synthetic resins, and the like, may also be used to secure the several partsv together. The composite structural end sections have longitudinal keyways receiving unitary or split double keys to permit their proper alignment and initial securing together, and they are provided further at the free edges with locking flanges adapted to receive flat keying members. With the use of such keying members abutted and aligned units may be permanently locked to give a wall, flooring or roof construction having a single face supported on composite structural stud or beam members. The fiat locking keys may have furring strips, sleepers or nailing members secured thereto at the open sides or faces of the assembled units, and .nailable surfacings may be secured to thefurring strips or sleepers. Such a construction permits the use of the customary nailable surfacingssuch as sheathings and clapboarding, plywood or. other paneling, and the like, to structural units, including my selfsupporting units generally, and the composite 50 structural stud, stanchion, and beam members of walls and fioorings. This provides a desired and practicable extension of the building principles and structures set out in my prior patents.

The use of an open-faced structural member having two structural end sections lends itself very readily to use in so-called prefabricated or preformed houses, in which the several parts may be designed or cut for rapid and efficient assembly and fabrication. As an adjunct of this facility of design, fabrication, and erection, the inner or outer panels of any given wall, fioor, ceiling, or attic unit, may be suitably stenciled to indicate diagrams for the layout and erection of plumbing pipes and fixtures, piping and other fixtures for heating systems and air conditioning devices, which diagrams will indicate the proper position of various services and component parts when the house is under erection. It will, of course, be appreciated that a wide variety of plans, layouts and diagrams, including catalogue designations of parts and bills of materials, may be stencilled, printed, or lithographed on either or both sides of these panel members. Such indicia may include diagrams for radio installations, television, fire-alarm, burglar alarm, telephone wiring or call bell systems, wiring diagrams or plans of a multitude of other devices, services or wiring layouts, diagrams or plans. The panels may, of course, include, nailing diagrams. In addition, the present invention comprehends the marking of the outer surfaces of such panels with diagrams, and thelike, indicating the position of sinks, flush tanks, lavatories, bowls, fixtures for telephone and lighting, including switches and switch control boxes, as well as brackets and hangers, and other auxiliary structural elements associated with the services delineated on the reverse side of the panel.

The composite structural members of the present invention include bipartite I-beams having fiat edge flanges and centrally disposed longi- 'tudinal keyways, usually of cylindrical crosssection, and adapted to receive unitary or split keys of like cross-section; Panel members will be secured to the flanges on one side of the members and the other edges or flanges will receive separate keying means which common keying means will include associated members for receiving continuous wall, floor and ceiling surfacings.

These and other desirable features and advantages of the present invention will be described hereinafter with respect to the drawing accompanying the present specification and. forming a part thereof, it being understood that the examples set forth are given by way of illustration only, for, since the underlying principles may be embodied in other specific structural devices, it is not intended to be limited to the structures here shown, except as such limitations are clearly imposed by the appended claims.

In the drawing, like numerals refer to similar parts throughout the several views, of which Fig. 1 is an elevation of a plurality of assembledwall units, partly in broken section, having floor hanging connections and composite structural supports with cylindrical keyways and common keying means therefor;

Fig. 2 is a detail, in plan view, of a joint connection for abutted three-part units, and.

Fig. 3 is a detail of the key locking means showing split keying members.

Referring now to the drawing, the structural members of the present invention comprise building units, I00, including single panel or Wall sections, IOI, secured to and spacing composite end stud members designated generally by the numeral 300. The composite studs or structural members, 300, include symmetrical channelshaped structural elements 30I, having flanged sides, 302, 303. The elements 30I also include central longitudinal keyways, usually of cylindrical cross-section, and disposed on the inside: of the channels formed by the edges or flanges, 303. Separate double cylindrical edges or beaded keys, 305, have edge or bead sections, 300, conformed to the keyways, 304, and are adapted to look a pair of abutted elements 30! together to form a composite I-beam, 300. Where desired, and as shown more particularly in Fig. 3, keying members, 305, may be substituted for by a pair of split keying members, 305a, each permanently associated and fitted in its respective keyway, 304. The split key members, 305a, include the edge bead sections, 306a, and fins or key sections, 301, formed coextensive therewith. The sections, 301, are in turn provided with continuous wedge-shaped sections, 308, formed with detent or hook portions, 309. When a pair of elements, 30I, are moved together so that the edges 308 of the split-keys, 305a, contact and slide over each other until the hook portions, 309, mutually engage, the two elements will be held firmly and a composite I-beam, 300, formed. This is in contrast to the structure shown in Fig. 1 and Fig. 2 wherein the keys, 305, are slid lengthways into the keyways, 304, of the mutually abutted I-beam segments, 30I. It will be noted further that the keying members 305a, serve substantially as automatic coupling members when building units, I00, are moved laterally into mutual locking engagement.

Panel members, IOI, of the unit are secured to side flanges, 302, of the stud or beam sections as by means of bolts or rivets or the like, all designated generally by the numeral I02. The web sections of elements 30I may be provided with a variety of apertures, all designated generally by the numeral IIOa.

The open faces of the abutted and aligned units, I00, are held locked together by the key members, I20, coacting with the hook flanges, 303, of the rail sections of the composite stud member, 300. On and over the sleepers, I30, which are secured to the key members, I20, may be applied a continuous wall surface or covering including inner sheathing-s, I32, over which may be applied any suitable plastic or other surfacing material, designated generally by the numeral I 33. Other surfacings may be applied thereto, and including metal, wood, paper-encased gypsum panels, plaster or stucco lath, which latter may be covered with plastic materials, or brick or stone veneer. The continuous sheathing or other like structural wall surfacing completes the wall structure and insures rigidity to the wall assemblies. The material used for the sheathing and surface finishings may vary, depending upon whether or not the'units form part'of inner supporting or partition walls, or whether they form part of outside walls, which are required to be finished with weather resistant surfacings; In the latter instance, it will be understood that tar paper and other waterproofing inserts may be associated with the sheathing, I32, and the sur face finishing, I33. Furring strips or sleepers,

:rectly abutted to give a line seam IOIa, particularly in cases where the paneling material, IOI, may be made of veneering and having a desirable surface finish. Any seams or joints formed may be filled with filler putty or cement and sparkled before painting or finishing of the surface.

The units, I00, may be set in channel members adapted to receive the composite stud members, 300, and secured therein by concrete or other hardenable plastics, or by mechanical means such as bolts and nuts, as well as by rivets and by means of spot welding. Usually and desirably the panel members, IOI, will be cut away a sufficient distance top and bottom to permit the composite structural members, 300, to extend therebeyond and fit into the channels at the bottom and receive cap members at the top as well as to receive at the top and bottom floor hanger members, I40. These hanger members comprise a generally continuous body section, I4I, secured to the stud members as by means of spot welds, Hi2, and being provided at the top and bottom thereof with an ofiset flange, I43, and a hook flange, I44, which are generally in vertical alignment. The flanges, I43, I44, of the hanger member, I40, are adapted to be received in and be locked by like members placed in reverse position on floor sections and other building members which are to be hung on the wall. The hangers may be secured on and over abutted panels, IOI, being directly welded to flanges, 302, the panels being cut away a sufficient distance to permit direct abutment. As shown in Fig. 1, the hangers may be laid over the panels and secured by fastening means, I Ma. The hanger members and the method of forming wall and floor joints therewith are described and claimed in my copending application, Serial No. 108,956, filed November 3, 1936, for Buildings and mechanical joints therefor, and will not be described further herein, except to show the general combination with the structural building units. In this connection, it is to be noted that the hanger members, I40, act as horizontal bracing members for each unit, and, thus, for the entire structure, and will prevent weaving or lateral vibration, particularly at the vertical joints. The hanger members may also be used in continuous lengths, overlapping or extending over a plurality of abutted units, and providing a common, lateral bracing construction.

As more particularly set forth and claimed in my companion application (D604:1), filed of even date herewith, a desirable feature in the designing and erection of so-called prefabricated or planned houses is the provision of stencillings on the inner surfaces of the wall panels, IOI, which stencillings indicate the exact position and layout of all plumbing, heating, air conditioning ducts, wiring'and telephone and other maintenance services required in a house. These several stencillings may vary from one unit to another, depending upon the parts which are to be secured therein or thereto and with absolute accuracy of fit and correctness of performance. It is to be noted further that all holes may be pre-drilled or pre-punched, and, where necessary, the holes receiving screw-fastening members may' be thread tapped. The pre-punched or pre-drilled holes will provide for the passage of pipe ducts, wires, and other elements, through the panels, thereby cutting down the time normally required for such work to be done in the field, and doing away with the botchy appearance of such work. All of this lends to uniformity of design, fabrication and erection, and, at the same time, insures to all parties involved maximum speed in erection and fitting, while, at the same time, insuring absolute correctness in the assembly, which, from the sanitary point of View, as well as of efliciency and safety, is of prime importance.

Standardization of erection, consequent upon the standardization of parts permitted by this novel method, also permits standardization of replacement members and absolute and complete accuracy in their identification and replacement. The plumbing and other services may have their outiets on either surface of the units and may extend through several units horizontally, passing through the apertures, IlOa, in the supporting members, 300. i

It will now be appreciated that there have been provided novel structural, building members, including unitary constructions having a paneling and structural end members secured thereto,

abutted end members of adjacent sections forming composite structural members, which, in turn, are locked in place by a plurality of keying members, one of which has means associated therewith to receive a continuous wall; wall surfacings, closing the open faces of the units and completing a wall, floor or roof assembly. In addition, floor hanging and securing members are associated with the assembly of units to secure floors thereto, and, at the same time, to provide a desirable lateral bracing to a structure made therefrom.

What is claimed is:

1. A composite structural building member forming a generally I-beam construction, comprising a pair of half elements each being of channel shape and each including a base or web portion having a longitudinal keyway therein, the said channels being juxtaposed to form a composite I-beam and stud member, keying means in the keyways locking the channels together; flat rail sections or flanges at the sides of the channels, flat keying members disposed on and over the aligned rail sections at one side of the composite member, the other flanges of abutted members being adapted to receive panel sections of building members.

ing members in the keyways and adapted to be mutually interlocked on lateral abutting movement of the web section.

3. A self-supporting building unit comprising a panel section secured to and spacing end structural sections, the end structural sections being elements of a composite I-beam construction, each section being a channel shape having a longitudinal keyway in the base thereof and adapted to abut like sections of juxtaposed elements and be keyed thereto by common keying members, the channel sides forming rail sections or flat flanges of the composite 'member, the flanges of one rail section being adapted to be engaged and secured by cooperating flat keying members, and the other rail flanges being secured to the said panel section.

4. A self-supporting building unit comprising a panel section secured to and spacing end structural sections, the end structural sections being elements of a composite I-beam construction, each section being a channel shape having a longitudinal keyway in the base thereof, asplit keying member in each said keyway and adapted to interlock with like members of juxtaposed end sections to form composite I-beam members, each channel side forming rail sections or flat flanges of the composite member, the flanges of one rail section being adapted to be engaged and secured by cooperating flat keying members, and the other rail flanges being secured to the said panel section.

5. In a building unit as claimed in claim 3, the improvements comprising floor and wall hanger members secured to and between spaced end sections.

6. In a building unit as claimed in claim 4, the improvements comprising floor and wall hanger members secured to and between spaced end sections.

'7. A continuous building section comprising an array of self-supporting building units, each unit including a single face or panel section secured to and spacing end structural elements of composite I-beams, each I-beam element being a channel shape having a longitudinal keyway in the base thereof and abutting like sections of juxtaposed elements and keyed thereto by common keying members, the channel sides forming rail sections or flat flanges of the composite member, the flanges of one rail section being engaged and secured by cooperating flat keying members, and the other rail flanges being respectively secured to unit panel sections.

8. In a building construction of the type described in claim '7, the improvements comprising a common wall surfacing over the open faces of the said assembly of units and secured to and on the end structural members.

9. In a building construction of the type described in claim 7,the improvements comprising a common wall surfacing over the open faces of the said assembly of units and secured to and on the end structural members, and structural hanger members secured to and on the panel side of the structural members at floor levels and forming lateral bracing elements for the building units.

10. In a building construction of the type described in claim 7, the improvements comprising a wall surfacing over the open faces of each unit of the said assembly of units and secured to and on the said structural members, and structural hanger members secured to and on the structural members at floor levels and forming lateral bracing elements for the building units.

11. A continuous building section comprising an array of self-supporting units, each unit including a single face or panel section secured to and spacing end structural elements of composite I-beams, each I-beam element being a channel shape having a longitudinal keyway in the base thereof, a split keying member in each said keyway and adapted to interlock with like members of juxtaposed end sections to form composite I-beams, each channel side forming rail sections or flat flanges of the composite member, the flanges of one rail section being engaged and secured by cooperating flat keying members, nailable members on the flat keying members, and floor and wall hanger members secured to the panel sides of the units.

12. In the construction of claim 11, wall surfacings secured to and on the nailable members.

GUY FELDI KOTRBATY. 

